Cleated article of footwear and method of manufacture

Abstract

A cleated article of footwear includes a chassis assembly having a sole plate having a plurality of bosses extending from a lower surface thereof. A heel counter extends upwardly from a heel portion of the sole plate. An outer assembly is secured to the chassis assembly and includes a sole portion and an upper secured to the sole portion. A plurality of cleats extends downwardly from a lower surface of the sole portion. Each of a plurality of apertures extends downwardly into a corresponding cleat and receives a boss.

1. A cleated article of footwear comprising, in combination:
 a chassis assembly comprising
 a sole plate having a plurality of bosses extending from a lower surface thereof; and 
 a heel counter extending upwardly from a heel portion of the sole plate; and 
 
 an outer assembly secured to the chassis assembly and comprising:
 a sole portion 
 a layer of adhesive on an upper surface of the sole portion bonding and securing the sole portion to a lower surface of the sole plate, such that the sole portion is fully bonded and fully secured to the sole plate; 
 an upper secured to the sole portion; 
 a plurality of cleats extending downwardly from a lower surface of the sole portion, each cleat having a recess formed therein; and 
 a plurality of apertures formed in the sole portion, each aperture aligned with a corresponding recess, each boss extending through a corresponding aperture and captured within a corresponding recess. 
 
 
   
   
     2. The cleated article of footwear of  claim 1 , wherein the heel counter is secured to the sole plate with an adhesive. 
   
   
     3. The cleated article of footwear of  claim 1 , wherein the outer assembly is secured to the chassis assembly with an adhesive. 
   
   
     4. The cleated article of footwear of  claim 3 , wherein the adhesive is heat activated. 
   
   
     5. The cleated article of footwear of  claim 1 , wherein at least one of the cleats is injection molded onto the sole portion. 
   
   
     6. The article of footwear of  claim 1 , wherein cleats in a midfoot portion and a heel portion of the sole portion are injection molded onto the sole portion. 
   
   
     7. The cleated articled of footwear of  claim 1 , wherein at least one of the cleats is secured to the sole portion with an adhesive. 
   
   
     8. The cleated article of footwear of  claim 7 , wherein the adhesive is heat activated. 
   
   
     9. The cleated article of footwear of  claim 1 , wherein cleats in a toe portion of the sole portion are secured to the sole portion with an adhesive. 
   
   
     10. The cleated article of footwear of  claim 1 , wherein the upper portion is secured to the sole portion by stitch and turn stitching. 
   
   
     11. The cleated article of footwear of  claim 1 , further comprising a heel pad positioned within the heel counter. 
   
   
     12. The cleated article of footwear of  claim 1 , further comprising an insole positioned within the outer assembly. 
   
   
     13. The cleated article of footwear of  claim 1 , wherein two pairs of bosses are positioned on the sole plate proximate a junction of a midfoot portion and a forefoot portion of the sole portion, one pair of bosses positioned on a lateral side of the sole portion and one pair positioned on a medial side of the sole portion, and two additional pairs of bosses are positioned in the heel portion of the sole plate, with one pair positioned on the lateral side and the other pair on the medial side of the heel portion of the sole portion. 
   
   
     14. The cleated article of footwear of  claim 1 , wherein a forefoot portion of the sole plate is formed of a first material and a midfoot portion and the heel portion of the sole plate are formed of a second material, the second material being more rigid than the first material. 
   
   
     15. A cleated article of footwear comprising, in combination:
 a chassis assembly comprising
 a sole plate having a plurality of bosses extending from a lower surface thereof; 
 a layer of heat activated adhesive on a lower surface of the sole plate; and 
 a heel counter adhesively secured to a heel portion of the sole plate; and 
 
 an outer assembly secured to the chassis assembly and comprising:
 a sole portion; 
 a layer of adhesive on an upper surface of the sole portion securing the sole portion to a lower surface of the sole plate; 
 an upper secured to the sole portion with stitch and turn stitching; 
 a layer of heat activated adhesive on an upper surface of the sole portion to fully bond with the layer of heat activated adhesive on the sole plate to fully secure and fully bond the outer assembly to the chassis assembly; 
 a plurality of cleats secured to a lower surface of the sole portion by direct injection, each cleat having a recess formed therein; and 
 
 a plurality of apertures formed in the sole portion, each aperture aligned with a corresponding recess, each boss extending through a corresponding aperture and captured within a corresponding recess. 
 
   
   
     16. A cleated article of footwear comprising, in combination:
 a chassis assembly comprising
 a sole plate having a plurality of bosses extending from a lower surface thereof; and 
 
 an outer assembly secured to the chassis assembly and comprising:
 a sole portion; 
 a layer of adhesive on an upper surface of the sole portion bonding and securing the sole portion to a lower surface of the sole plate, such that the sole portion is fully bonded and fully secured to the sole plate; 
 an upper secured to the sole portion; 
 a plurality of cleats extending downwardly from a lower surface of the sole portion, each cleat having a recess formed therein; 
 a plurality of apertures formed in the sole portion, each aperture aligned with a corresponding recess, each boss extending through a corresponding aperture and captured within a corresponding recess; and 
 a heel counter secured to an exterior surface of a heel portion of the upper portion.